Compact Secondary Substations (CSS)

For secure, reliable power distribution and space saving solutions

ABB – a global leader

ABB is a global leader in Power and Automation
technologies that enable utility and industry
customers to improve performance while lowering
environmental impact. The ABB Group of companies
operates in around 100 countries.
services for power generation, transmission and
distribution. ABB’s turnkey solution capabilities in the
sector range from bulk power transmission,
substations and complete electrification to utility
automation and distribution systems.

In India, ABB serves customers with the complete
range of power and automation technologies. The
company has a vast installed base, extensive
manufacturing and a countrywide marketing and
service presence.
The Power Technologies division offers electric, gas
and water utilities as well as industrial and commercial
customers a wide range of products, systems and
The product offering covers a wide spectrum of
technologies across the entire voltage range including
indoor and outdoor circuit breakers, air and gas
insulated switchgear, disconnectors, capacitor banks,
reactive power compensators, power distribution and
instrument transformers and a range of power
distribution products like Compact Substations
(CSS), Ring Main Units (RMU).

Advantage ABB

9 120 years of technology and innovation

9 Unparalleled domain competence
9 Vast global experience
9 Total solution provider
9 Large installed base
9 Environment-friendly technologies

2 ABB
Compact Secondary Substations (CSS)

Designed in accordance with IEC 61330 standards, Applications

the CSS is a prefabricated secondary substation
with type-tested equipment and includes a Secondary Application
distribution transformer, medium voltage switchgear, Substation
low-voltage switchboard, connections and Distribution Public distribution
associated equipment in a compact unit. The CSS is Operation At medium-voltage level
designed keeping in mind high levels of personal
Supply To satellite stations and major
safety and aesthetics as they are often located in
electricity customers
high density, urban centres.
Feeding Connection of decentralised
All components are housed in an enclosure, which power plant to the public
protects the equipment against environmental network
hazards and unauthorised access. The enclosure is
Satellite Substations for the end of
typically divided into three sections or radial connections
compartments – medium voltage switchgear, low
Pylon feeder Smaller stations
voltage switchboard and distribution transformer.
station connected to overhead lines
The substation can be operated from the inside
(Walk-in type) or from the outside (Non Walk-in type).
The electrical equipment is cooled by natural
Type designations (example)
ventilation through openings in the substation.

The standard degree of protection for CSS is IP23D Product type

in accordance with IEC 60529 standards. If required, CSS = Compact Secondary
CSS can be supplied with doors that comply with Substation
IP54 standards, by including gaskets and excluding
Materials
the door ventilation openings.
S = Steel C = Concrete

Key features Layout

W = Walk-in N = Non Walk-in
„ Wide modular product range
C = Compact
„ Enhanced safety
Width
„ Several options and extensive flexibility
Number of modules wide
„ Appealing aesthetics
Length
„ Reduced overall plant and operating costs
Number of modules long

CSS-S C - X - Y

Quality
The entire CSS range is manufactured in accordance with parts. The galvanised steel foundation is bolted to the
ABB’s stringent quality and environmental (ISO 9001 and structure. The result is a fully earthed enclosure,
ISO 14001) standards. providing a high level of personal safety.

Personal safety Protection

All live parts in the CSS range are protected against
unintentional contact by means of lockable doors.
Cable connections and fuses in the medium voltage
room are also protected against unintentional contact.
Anti-contact protection is tested in accordance with
IEC 61330. Clinched or screwed connections form
electrical connections with all of the station’s metal
The substation is subjected to moisture, condensation
and dirt. In coastal locations sea salt on the surface of
open, insulated surfaces can cause leaking current,
which can result in a flashover. Accordingly, the CSS is
designed and fabricated using material and equipment
capable of withstanding harsh climatic and operational
conditions.

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Product overview

The CSS consists of modular components which makes it possible to custom design the equipment based
on customers’ requirements. The solutions shown below are a few examples of the many options.

Model CSS-SW
Walk-in station. Surface mounted and operated from the inside.

Model CSS-SN
Non-walk-in station. Surface mounted and operated from the outside.

Model CSS-SC
Compact station. Installed partially below the ground and operated from the outside.

Legend

Low voltage Medium voltage Distribution

switchboards switchgear transformer

4 ABB
Design

Modular structure Clinching technology for maximum strength is

The enclosures of CSS consist of 300mm wide
modules (M) and plus corner sections measuring
115x115 mm. The walls are supplied in four different
heights and the roofs with two angles of pitch, 6o
and 18o. The doors are 2, 3 or 4 m wide and can be
fitted as either single or double doors. The ventilation
doors are 2 or 3 m wide.
Standard building sizes
used to assemble the walls and the roof. Lifting
fittings, corner sections, bearing sections, base
plates and cable covers are assembled using bolts.
The low voltage switchboard and the medium
voltage switchgear are bolted to the structure. The
roof, the walls and doors are constructed from 1.5
mm galvanised sheet steel and the CSS is painted
with two coats of polyurethane paint.
Foundation or base frame

W = Width 4M 5M 6M 7M
External width, steel (mm) 1430 1730 2030 2330

L = Length 5M 6M 7M 8M The CSS models designed for installation at ground

External length, steel (mm) 1730 2030 2330 2630
level have a 130mm high base frame. The models for
L = Length 9M 10 M 11 M 12 M
installation partially below ground level are supplied
External length, steel (mm) 2930 3230 3530 3830
with foundations at three different heights: 528mm,
778mm or 978mm, depending on the size of the
H = Wall height (mm) 1266 1664 1914 2114
transformer. The foundation and base frame are
produced using 2mm G.I. Sheet.
R = Roof height (mm) Width of building
4M 5M 6M 7M
6° roof pitch 203 219 235 251
18° roof pitch 365 414 463 512

The CSS comes in standard sizes and other

customised sizes can be supplied on request.

The Enclosure
The enclosure is typically divided into three
compartments for the medium voltage switchgear,
low voltage switchboard and distribution
transformer. All standard modules of walls, doors
and ceilings are produced using roller formed
sections. The detachable roof with ventilation
openings is supported by a beam and secured to
the corner sections with bolts.
Standard doors are fitted with handles and bolts for
padlocks. The doors are closed by means of a two-
point device, which secures the door to the top
frame and the base frame. The doors are fitted with
stainless steel hinges and with door stoppers. The
wall and roof modules are assembled by means of a
self-locking mechanism.

ABB 5
 Oil collection pit
When the CSS is installed partly below the ground,
an integrated oil collection pit made from 1.5 mm
galvanised steel is a standard feature. A separate oil
collection pit for stations installed at ground level can
be supplied. The distribution transformer is fitted in
the oil collection pit, which has a volume of at least
20% of the transformer’s oil volume. The oil
collection pit provides protection against oil pollution
in case of a leak in the transformer. The oil pit is
normally supplied as per IE regulations where the
transformer oil capacity is >2000 litres.
Ventilation
Ventilation is achieved by means of natural air
circulation of air from the top of the roof to the lower
part of the doors that contain ventilation openings.
Sufficient cooling of the distribution transformers is
achieved by means of ventilation openings in the
transformer room that are designed considering
transformer rating, losses and climatic conditions.
A standard CSS is classified and type tested in
accordance with temperature class K20.
Temperature class K10 can be achieved for all
ground level substations by means of additional
ventilation that can be achieved by increasing the
ventilation area of the transformer room.

The oil collection pit

Ventilation openings in the doors

Partitioned roof
The standard roof of up to 3.8 m in length can be
detached in one piece. A partitioned roof can be Other options available
supplied for stations over 3 m. CSS CSS CSS
Functionality SW SN SC
Doors
Concrete slab as base „ „
Standard doors are designed for padlocks and can
also be fitted with a cylinder lock.
Doors with IP54 protection „ „ „

Protection
Temperature class K10 „ „
To provide protection against dust in the medium-
voltage and low-voltage compartments, the doors „ „ „
Earthing system up to 20 kA
can be fitted with gaskets that increase the degree of
protection to IP54. Partitioned roof (longer than 3 m) „ „ „

Cylinder lock in doors „ „ „

Aluminium foundation plates „

Snow panel below doors „ „

6 ABB
Electrical equipment in the CSS

Medium voltage switchgear Distribution transformer

The CSS range has been designed and type tested CSS stations are designed to house distribution
with ABB’s medium voltage switchgear and can transformers up to 1250 kVA / 24 kV:
house the following: „ Oil-insulated model, hermetically sealed
„ Ring Main Unit SafeRing 12-24kV „ Oil-insulated with oil conservator
„ Fuse-switch disconnectors The CSS can be supplied
with a pre-installed
The range of medium
distribution transformer.
voltage switchgear
The possibility of lifting the
includes both
substation with the
pre-configured and fully
transformer depends on
configurable gas-
the type of station, the
insulated solutions. A
relevant solution and the
high level of personal
transformer size.
safety is ensured using
type tested equipment. Cables and cable accessories
CSS is supplied with internal cables / terminations:
Low-voltage switchboard „ Medium-voltage cables from medium-voltage
CSS is designed to house various low voltage switchgear to the distribution transformer
solutions in accordance with standard norms and „ Low-voltage cables / busbars from low-voltage
regulations, as well as individual requirements. The
switchboards to the distribution transformer
product range includes various types of fuse-switch
disconnectors, including DIN solutions and moulded SF6 gas-insulated medium-voltage switchgear is
case circuit connected using elbow connections. The cable
breakers. Other termination to the transformer is through regular
equipment can be cable adapters or, if required,
supplied as per elbow connections. The low-
customer voltage cable / busbars
specifications. between the distribution
transformer and the low-
voltage switchboard are fitted
with the necessary
terminations.

Type test
The CSS range is designed and type tested in The main components are type tested in accordance with
accordance with IEC 61330, which covers the following their individual standards:
test programmes:
„ Control of insulation level Medium-voltage switchgear
„ Control of temperature rise in the main components in „ IEC 60265: High-voltage switches
the substation
„ IEC 60298: Metal-enclosed high-voltage switchgear
„ Control of earthing system
„ Control of internal protection class „ IEC 60694: High-voltage switchgear
„ Control the building resistance to mechanical effects
„ Function tests on mechanical parts Low-voltage switchboard
„ IEC 60439: Low-voltage switchgear and control gear
Additional type tests in accordance with IEC 61330:
„ Rated short-time current test
Distribution transformer
„ Noise test
„ IEC 60076: Power transformers
„ EMC test

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ABB Limited Regional Marketing Offices:
Medium Voltage
Power Technologies North West South
Plot No. 79, Street No. 17
MIDC Area, Satpur NBCC Tower ABB House Embassy Star, 1st Floor
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